Hi, can any one share a document which shows advantages of PM891 over AC450 controller ?
I am presently working in a plant which has 5 nos AC 450 controllers installed way back in 1997.
I would like to propose my management to upgrade the AC 450 controllers with PM891, by giving them the essence of what will be benifits if we upgrade to PM891.
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You could obtain the most realistic information from end-user who already passed upgrade of AC450 to AC800M at their plant. I'll ask head of maintenance of the plant where we upgraded 5 AC450 this year for opinion. If you are interested, please send me your email to herman(at)datakon(dot)sk .
- Upgrade of AC450 will bring much more efficient maintenance. You can avoid night visits of the plant if you ask future vendor for more informative interlock graphics which can discover pending process interlock without checking in Online builder egineering PC.
- Every process logic modification is much more efficient in AC800M than in AC450.
- AC800M supports many communication protocols hence is much easier connection to the external PLCs or sensors
- if your HMI is old AS500 still then new 800xA brings you amazing improvement of operator effectiveness. Many ABB related pdfs are available for download
The most efficient AC450 upgrade is automated conversion combined with thorough tests of converted logic. It is also possible to perform test of AC800M connected in parallel with AC450 during production in order to compare outputs from old&new system (shadowing). This is the most efficient method of the new system verification if bumpless replacement AC450 to AC800M is required - as we did in our last upgradation project.
I hope this helps a bit
Do you want an honest and realistic answer .... ?
Any document you get from a salesman is junk. There is only one real argument that will sell a new control system to your management - it has to be cheaper than keeping your existing AC450.
- Get a quote for a replacement.
- Dont forget the cost of replacing I/O and all the other things that may not be supported by a PM891.
- Account for retraining your support staff, learning support skills, licenses, programming, re-commissioning etc.
- Account for the disruption to your business caused by downtime for replacing the system and starting up the new controllers.
- Compare this with the cost of continuing to run your existing AC450 controllers for "x" years, where X is the payback period your accountants use.
When you add all the costs up, there is rarely a genuine case for replacing a well cared for AC450 controller. And if there is, then management will rightly demand that you compare the costs of an upgrade from more than one supplier.
The PM891 is an excellent choice for EXPANDING your existing control system. It shares a common HMI in 800xA and it can use many of the same I/O and bus components. It is also able to communicate on the MB300 directly to the AC450 controllers. AC800M controllers are also very good replacements for older PLC's you may have on site. Once you have one PM891, it becomes a more obvious choice to replace your AC450 with more when they eventually do become end-of-life. But right now the AC450 is still a supported product.
As someone wih 35 years experience of AdvantMaster, and lately AC800M, configuration, I have to agree with Rob on this one. Your main justification for such an extensive undertaking would have to be end-of-life of the AC450, but since, as Rob points out, the AC450 is still an actively supported product, you can not use that argument. Since your system was put in in the 1990s, your AC450 hardware and firmware is likely not up-to-date, and you should definitely consider bringing it up to the latest, supported versions. I have seen MasterPiece installations, where end-of-life is a fact, go both ways, upgrade to AC450 or replace with AC800M. Both customers are happy with the end result, and as far as the AC800M goes, I think there is a realization that you went from one set of quirks and shortcomings, to a new set of quirks and shortcomings. I would hesitate to call an AC450 to AC800M replacement an upgrade, replacement is more accurate. That said, with AC800M you get a few things that can be beneficial; more communication protocols, like MODBUS TCP, more flexible trending, some extended functionality to familiar Function Blocks like MOTCON and PIDCON if you use the Pulp and Paper Library for AC800M to name a few. Engineering tools-wise you will get live data for a whole page instead of a single element, which in my experience is less useful than you might think, but you will miss the highly useful GETAB in both graphic and list mode for example. A well structured workflow for AC450, leveraging the full power of Function Chart Builder together with the Online Builder, and the power of Online Builder Command Procedures, is hard to beat with Control Builder M, or Function Designer, which I have used extensively. AC800M projects normally take me about 4 times as long as AC450 projects for control configuration. So in brief, carefully consider the full cost of a replacement, and the limited benefits you may gain, as well as what you may lose.